US7842629B2 - Non-woven glass fiber mat faced gypsum board and process of manufacture - Google Patents

Non-woven glass fiber mat faced gypsum board and process of manufacture Download PDF

Info

Publication number
US7842629B2
US7842629B2 US10/608,790 US60879003A US7842629B2 US 7842629 B2 US7842629 B2 US 7842629B2 US 60879003 A US60879003 A US 60879003A US 7842629 B2 US7842629 B2 US 7842629B2
Authority
US
United States
Prior art keywords
gypsum board
mat
recited
fibers
web
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US10/608,790
Other languages
English (en)
Other versions
US20040266304A1 (en
Inventor
Alan Michael Jaffee
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Johns Manville
Original Assignee
Johns Manville
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johns Manville filed Critical Johns Manville
Priority to US10/608,790 priority Critical patent/US7842629B2/en
Assigned to JOHNS MANVILLE INTERNATIONAL, INC. reassignment JOHNS MANVILLE INTERNATIONAL, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JAFFEE, ALAN MICHAEL
Priority to TR2018/19200T priority patent/TR201819200T4/tr
Priority to EP04754709.6A priority patent/EP1644167B1/fr
Priority to CA 2529627 priority patent/CA2529627C/fr
Priority to PL04754709T priority patent/PL1644167T3/pl
Priority to RU2006102359A priority patent/RU2348532C2/ru
Priority to PCT/US2004/018178 priority patent/WO2005005117A2/fr
Priority to ES04754709T priority patent/ES2711228T3/es
Publication of US20040266304A1 publication Critical patent/US20040266304A1/en
Publication of US7842629B2 publication Critical patent/US7842629B2/en
Application granted granted Critical
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0092—Machines or methods for applying the material to surfaces to form a permanent layer thereon to webs, sheets or the like, e.g. of paper, cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0006—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects the reinforcement consisting of aligned, non-metal reinforcing elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B32B17/04—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments bonded with or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/16—Drying; Softening; Cleaning
    • B32B38/164—Drying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C04B28/145—Calcium sulfate hemi-hydrate with a specific crystal form
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C04B28/16—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements containing anhydrite, e.g. Keene's cement
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B32B2317/122—Kraft paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B32B2607/02—Wall papers, wall coverings
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C04B2111/0062—Gypsum-paper board like materials
    • C04B2111/00629—Gypsum-paper board like materials the covering sheets being made of material other than paper
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/603—Including strand or fiber material precoated with other than free metal or alloy
    • Y10T442/604—Strand or fiber material is glass
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
    • Y10T442/615—Strand or fiber material is blended with another chemically different microfiber in the same layer
    • Y10T442/616—Blend of synthetic polymeric and inorganic microfibers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
    • Y10T442/615—Strand or fiber material is blended with another chemically different microfiber in the same layer
    • Y10T442/618—Blend of chemically different inorganic microfibers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/614—Strand or fiber material specified as having microdimensions [i.e., microfiber]
    • Y10T442/623—Microfiber is glass
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/647—Including a foamed layer or component
    • Y10T442/652—Nonwoven fabric is coated, impregnated, or autogenously bonded
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/665—Including a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/697—Containing at least two chemically different strand or fiber materials
    • Y10T442/698—Containing polymeric and natural strand or fiber materials

Definitions

  • the present invention relates to a gypsum board used in building construction and to a process for its manufacture; and more particularly, to a non-woven glass fiber mat comprising a blend of glass fibers having different diameters and lengths bonded together with a resinous latex binder, a gypsum board or similar product in panel form faced on at least one side with such a mat, and processes for the manufacture thereof.
  • Wallboard formed of a gypsum core sandwiched between facing layers is used in the construction of virtually every modern building.
  • the material is employed as a surface for walls and ceilings and the like, both interior and exterior. It is relatively easy and inexpensive to install, finish, and maintain, and in suitable forms, is relatively fire resistant.
  • paper-faced wallboard is most commonly used for finishing interior walls and ceilings, other forms with different kinds of facings have superior properties that are essential for other uses.
  • One known facing material is non-woven fiberglass mat.
  • Gypsum wallboard and gypsum panels are traditionally manufactured by a continuous process.
  • a gypsum slurry is first generated in a mechanical mixer by mixing at least one of anhydrous calcium sulfate (CaSO 4 ) and calcium sulfate hemihydrate (CaSO 4 .1 ⁇ 2H 2 O, also known as calcined gypsum), water, and other substances, which may include set accelerants, waterproofing agents, reinforcing mineral, glass fibers, and the like.
  • the gypsum slurry is normally deposited on a continuously advancing, lower facing sheet, such as kraft paper.
  • Various additives e.g.
  • cellulose and glass fibers are often added to the slurry to strengthen the gypsum core once it is dry or set. Starch is frequently added to the slurry in order to improve the adhesion between the gypsum core and the facing.
  • a continuously advancing upper facing sheet is laid over the gypsum and the edges of the upper and lower facing sheets are pasted to each other with a suitable adhesive.
  • the facing sheets and gypsum slurry are passed between parallel upper and lower forming plates or rolls in order to generate an integrated and continuous flat strip of unset gypsum sandwiched between the sheets. Such a flat strip of unset gypsum is known as a facing or liner.
  • the strip is conveyed over a series of continuous moving belts and rollers for a period of several minutes, during which time the core begins to hydrate back to gypsum (CaSO 4 .2H 2 O).
  • the process is conventionally termed “setting,” since the rehydrated gypsum is relatively hard.
  • the strip is stressed in a way that can cause the facing to delaminate from the gypsum core if its adhesion is not sufficient.
  • the continuous strip is cut into shorter lengths or even individual boards or panels of prescribed length.
  • the gypsum boards are fed into drying ovens or kilns so as to evaporate excess water. Inside the drying ovens, the boards are blown with hot drying air. After the dried gypsum boards are removed from the ovens, the ends of the boards are trimmed off and the boards are cut to desired sizes.
  • the boards are commonly sold to the building industry in the form of sheets nominally 4 feet wide and 8 to 12 feet or more long and in thicknesses from nominally about 1 ⁇ 4 to 1 inches, the width and length dimensions defining the two faces of the board.
  • paper While paper is widely used as a facing material for gypsum board products because of its low cost, many applications demand water resistance that paper facing cannot provide. Upon exposure to water either directly in liquid form or indirectly through exposure to high humidity, paper is highly prone to degradation, such as by delamination, that substantially compromises its mechanical strength. Gypsum products typically rely on the integrity of the facing as a major contributor to their structural strength. Consequently, paper-faced products are generally not suited for exterior or other building uses in which exposure to moisture conditions is presumed.
  • the paper facing of conventional gypsum board contains wood pulp and other organic materials that may act in the presence of moisture or high humidity as nutrients for such microbial growth. A satisfactory alternative facing material less susceptible to growth is highly sought.
  • a further drawback of paper-faced gypsum board is flame resistance.
  • the exposed paper facing quickly burns away.
  • the board's mechanical strength is greatly impaired.
  • the board is highly likely to collapse, permitting fire to spread to the underlying framing members and adjacent areas of a building, with obvious and serious consequences.
  • a board having a facing less susceptible to burning would at least survive longer in a fire and thus be highly desirable in protecting both people and property.
  • U.S. Pat. No. 4,647,496 discloses an exterior insulation system including a fibrous mat-faced gypsum board having a set gypsum core that is water-resistant.
  • the fibrous mat is preferably sufficiently porous for the water in the gypsum slurry to evaporate during the production drying operation as the gypsum sets.
  • the mat comprises fibrous material that can be either mineral-type or a synthetic resin.
  • One preferred mat comprises non-woven glass fibers, randomly oriented and secured together with a modified or plasticized urea formaldehyde resin binder, and sold as DURA-GLASS® 7502 by the Manville Building Materials Corporation.
  • gypsum board products incorporating such conventional fibrous mats have proven to have certain drawbacks. While fibrous mats are undesirably more costly than the traditionally used kraft paper, there are other, more troublesome issues as well. Some persons are found to be quite sensitive to the fiberglass mat, and develop skin irritations and abrasions when exposed to the mat at various stages, including the initial production of the mat, the manufacture of composite gypsum board with the mat facing, and during the cutting, handling, and fastening operations (e.g., with nails or screws) that attend installation of the end product during building construction. Handling of the mat, and especially cutting, is believed to release glass fibers responsible for the irritation. The fibers may either become airborne or be transferred by direct contact. As a result, workers are generally forced to wear long-sleeved shirts and long pants and to use protective equipment such as dust masks. Such measures are especially unpleasant in the sweaty, hot and humid conditions often encountered either in manufacturing facilities or on a construction jobsite.
  • mat-faced gypsum board is known from U.S. Pat. No. 4,879,173, which discloses a mat of non-woven fibers having a reinforcing resinous binder that can comprise a single resin or a mixture of resins, either thermoplastic or thermosetting.
  • exemplary resins disclosed include a styrene-acrylic copolymer and a self-crosslinking vinyl acetate-acrylic copolymer.
  • a small amount of the binder is applied to the surface of the mat and penetrates but part of the way therethrough.
  • the board is said to be useful as a support member in a built-up roof.
  • the highly textured surface of the mat binder provides many interstices into which can flow an adhesive used to adhere an overlying component.
  • a fibrous mat facer with improved strike-through resistance and useful as a facer substrate or carrier for receiving a curable substance in a fluid state is disclosed by U.S. Pat. No. 4,637,951.
  • the porous, non-woven mat comprises a blend of microfibers intermixed and dispersed with base fibers and bound with a binder comprising a water miscible combination of a heat settable polymer.
  • the mat is said to be useful in forming composite materials employing a curable thermoset, preferably foamable material such as a polyurethane or polyisocyanurate rigid foam board and as a carrier web in the vinyl flooring industry where the settable polymer comprises a vinyl plastisol.
  • the present invention provides a gypsum board and a process for the manufacture thereof.
  • the board comprises a layer of set gypsum having a first face and a second face and a fibrous mat affixed to at least one of the faces.
  • the mat includes a non-woven web comprising a blend of a major portion composed of chopped continuous glass fibers having an average fiber diameter ranging from about 8 to 17 ⁇ m and a minor portion composed of fine staple fibers having an average fiber diameter of less than about 5.5 ⁇ m.
  • the minor portion comprises about 1-30 percent of the dry weight of the web.
  • the gypsum board of the invention typically is used for a number of purposes in building construction, such as a surface material for walls and ceilings and as an underlayment for floors, roofs, and the like.
  • the board finds application in both interior and exterior environments.
  • the board has a smooth, uniform surface that readily accepts paint or other surface treatments to provide a pleasing aesthetic appearance.
  • Various embodiments of the invention have further desirable attributes, including resistance to flame, moisture, and growth of mold and mildew.
  • the inadvertent release of fibers from the mat used in the present gypsum board is minimized, limiting the incidence of skin irritation among workers involved in either production or installation of the board.
  • FIG. 1 is a cross-sectional view of a mat-faced gypsum board of the invention.
  • the present invention provides gypsum board and other hydraulic set and cementitious boards having front and back large surfaces, at least one of which is faced with a non-woven, fibrous mat.
  • hydraulic set is meant a material capable of hardening to form a cementitious compound in the presence of water.
  • Typical hydraulic set materials include gypsum, Portland cement, pozzolanic materials, and the like.
  • FIG. 1 there is shown generally at 30 a sectional view across the width direction of one embodiment of a mat-faced gypsum board in accordance with the invention.
  • the board comprises a layer of set gypsum 28 , which is sandwiched between first and second fibrous mats 14 , 20 , and bonded thereto.
  • Two right-angled folds are formed in each lateral edge of first mat 14 , a first upward fold and a second inward fold. The two folds are separated by a small distance, whereby the thickness of board is generally determined.
  • the second folds define longitudinally extending strips 16 and 18 that are substantially parallel to the main part of the mat.
  • a second fibrous mat 20 covers the other side of the set gypsum core 28 .
  • second mat 20 The respective lateral edges of second mat 20 are affixed to strips 16 and 18 , preferably with adhesive 22 , 23 .
  • board 30 is installed with the side bearing mat 14 facing a finished space.
  • the board is advantageously ready for painting, but other finishing forms such as plaster, wallpaper or other known wall coverings may also be applied with a minimum of surface preparation.
  • the mats used in the present invention for one or both of the large faces of the gypsum board comprise a non-woven web bonded together with a resinous binder.
  • the web consists essentially of a blend of a major portion composed of chopped continuous glass fibers having an average diameter ranging from about 8 to about 17 ⁇ m and a minor portion composed of fine staple fibers, also called microfibers.
  • the minor portion comprises about 1-30 percent, and preferably about 20-30 percent, of the weight of the dry web.
  • the fine fibers have an average fiber diameter of less than about 5.5 ⁇ m, and preferably an average fiber diameter of less than about 3.5 ⁇ m, and more preferably less than about 1.9 ⁇ m.
  • the fine fibers preferably have a fiber length of less than about 7 mm.
  • the chopped strand fibers preferably have fairly uniform fiber diameters and lengths, although mixtures of different lengths and different fiber diameters are contemplated and included within the scope of the invention.
  • Chopped strand fibers are readily distinguishable from staple fibers by those skilled in the art.
  • Staple fibers are usually made by processes such as rotary fiberization or flame attenuation of molten glass known in the fiber industry. They typically have a wider range of lengths and fiber diameters than chopped strand fibers. Commonly the microfibers have a distribution of lengths ranging from a few times their diameters up to about 7 mm, with a few fibers as long as about 12 mm.
  • One method of making the fine fibers is disclosed by U.S. Pat. No. 4,167,404, which disclosure is hereby incorporated in the entirety by reference thereto.
  • fibrous mats containing a combination of chopped, relatively large diameter fibers and staple microfibers of lesser diameter conveys a number of advantages over boards made with other known fibrous mats.
  • the smaller fibers tend to fill the interstices between large fibers, thereby limiting the intrusion of gypsum slurry into and through the mat onto the board surface. Surprisingly, this control is achieved without unduly compromising the permeability of the mat for residual water vapor in the gypsum that must be removed during board production.
  • the distribution of chopped fiber diameters may have a single mode, but may optionally be multi-modal.
  • suitable arrangement of the distribution of fiber size affords further and more precise control of the porosity and air permeability of the fibrous mat and the corresponding propensity for bleed-through of the gypsum slurry.
  • the need for careful control of slurry viscosity during board production with the present mat is greatly eased, leading to cost reduction and manufacturing efficiency.
  • the surface of boards made in accordance with the present invention has an improved “hand,” i.e., an improved subjective feel, and better accepts surface treatments because of its greater smoothness. Even after prior art boards are coated with substantial amounts of paint in multiple coats, the texture of the facing mat in many instances remains visible, making the surface aesthetically unpleasing for many applications.
  • the present boards may be finished to provide an aesthetic and functional surface with far less paint and the associated labor to prepare the surface and apply the paint or other desired finish, wallpaper or other coating, or the like.
  • a preferred continuous glass fiber for the major portion of the fibrous web is at least one member selected from the group consisting of E, C, and T type and sodium borosilicate glasses.
  • E glass refers to a family of glasses typically with a calcium aluminoborosilicate composition and a maximum alkali content of 2.0% that are also known as electrical glasses.
  • E glass fiber is commonly used to reinforce various articles.
  • C glass typically has a soda-lime-borosilicate composition that provides it with enhanced chemical stability in corrosive environments
  • T glass usually has a magnesium aluminosilicate composition and especially high tensile strength in filament form.
  • the chopped fibers of the major portion can have varying lengths, but more commonly are substantially of similar length.
  • E glass fiber having an average fiber diameter ranging from about 10 to 16 ⁇ m and a length ranging from about 5 to 30 mm.
  • E glass fiber has sufficiently high strength and other mechanical properties to produce acceptable mats and is relatively low in cost and widely available.
  • Most preferred is E glass having an average fiber diameter of about 11 ⁇ 1.5 ⁇ m and a length ranging from about 6 to 12 mm.
  • the staple fibers used for the minor portion of the web are preferably glass or mineral fibers, such as mineral wool, slag wool, ceramic fibers, carbon fibers, metal fibers, refractory fibers, or mixtures thereof.
  • Other synthetic or polymer fibers such as melt blown micro denier fibers of polyester, nylon, polyethylene, polypropylene, or the like, may also be used.
  • the aforementioned fibrous mat comprising a blend of fibers be used for both facings of the board, one of the faces may also be formed with kraft paper, other glass mats, or other facings conventionally used in gypsum board.
  • Suitable binders include urea formaldehyde; conventional modified urea formaldehyde; acrylic resins; melamine resins, preferably having a high nitrogen resins such as those disclosed by U.S. Pat. No. 5,840,413; homopolymers or copolymers of polyacrylic acid having a molecular weight of less than 10,000, preferably less than 3,000; crosslinking acrylic copolymer having a glass transition temperature (GTT) of at least about 25° C., crosslinked vinyl chloride acrylate copolymers having a GTT preferably no higher than about 113° C.; and other known flame and water resistant conventional mat binders.
  • GTT glass transition temperature
  • Binder systems having a GTT ranging from about 15 to 45° C. are thus preferred.
  • Aqueous modified and plasticized urea formaldehyde resin binders may be used and have low cost and acceptably high performance.
  • the binder used for the present mats comprise an effective amount of a water repellant to limit the intrusion of gypsum slurry during board production.
  • vinyl acrylate latex copolymers may further incorporate stearylated melamine for improvement in water repellency, preferably at a level ranging from about 3 to 10 wt. %, and more preferably at about 6 wt. %.
  • a suitable aqueous stearylated melamine emulsion is available from the Sequa Chemical Corporation, Chester, S.C., under the tradename SEQUAPELTM 409. The stearylated melamine is in liquid form having a solids content of about 40 wt.
  • gypsum board incorporating mat with the preferred binder is more resistant to abrasion than board faced with either paper or conventional fibrous mats.
  • a preferred binder for the present mat comprises an acrylate copolymer binder latex with a GTT of about 25° C. available from Noveon, Inc. of Cleveland, Ohio, under the tradename HycarTM 26138.
  • this acrylate copolymer latex has a solids content of about 50 weight percent solids, but it is preferred to dilute the concentration with water to about 25 wt. percent solids before using it.
  • Preferably up to about 10 weight percent of a crosslinker such as melamine formaldehyde is added to the acrylate; and more preferably about 2 to 5 weight percent of crosslinker is added.
  • mat bound with the acrylate copolymer latex is smoother and the mat thinner for equivalent weight and properties than with other known binders.
  • expensive fluorochemical emulsions needed in prior art binders are not required.
  • the amount of acrylate copolymer latex binder (and any optional cross-linker) left in the wet mat during manufacture can be determined by a loss on ignition (LOI) test, the result thereof being specified as a percentage of the dry weight of the finished mat.
  • LOI loss on ignition
  • the amount of binder in the final mat ranges from about 15 to 35 wt. percent, with about 20-30 wt. percent being more preferred, and 25 ⁇ 2.5 wt. percent being most preferred.
  • the upper limit is dictated by process constraints and cost, while the minimum is required for adequate tensile strength.
  • the fibrous mats of the present invention further contain fillers, pigments, or other inert or active ingredients either throughout the mat or concentrated on a surface.
  • the mat can contain effective amounts of fine particles of limestone, glass, clay, coloring pigments, biocide, fungicide, intumescent material, or mixtures thereof.
  • additives may be added for known structural, functional, or aesthetic qualities imparted thereby. These qualities include coloration, modification of the structure or texture of the surface, resistance to mold or fungus formation, and fire resistance.
  • flame retardants sufficient to provide flame resistance, e.g. according to NFPA Method 701 of the National Fire Protection Association or ASTM Standard E84, Class 1, by the American Society for the Testing of Materials, are added.
  • Biocide is preferably added to the mat and/or gypsum slurry to resist fungal growth, measurable in accordance with ASTM Standard D3273.
  • Gypsum board in accordance with the present invention preferably is faced with a mat having a basis weight ranging from about 0.6 to 2.2 pounds per 100 square feet, more preferably ranging from about 0.9 to 2.2 lbs./100 sq. ft., and most preferably about 1.25 ⁇ 0.2 lbs./100 sq. ft. (about 29-110, 45-110, and 60 ⁇ 10 g/m 2 , respectively).
  • the binder content of the dried and cured mats ranges from about 10 to 35 wt. percent, more preferably from about 15 to 30 wt. percent, and most preferably from about 25 ⁇ 3 wt. percent, based on the weight of the finished mat.
  • the basis weight must be large enough to provide the mat with sufficient tensile strength for producing quality gypsum board.
  • the binder content must be limited for the mat to remain sufficiently flexible to permit it to be bent to form the corners of the board, as shown in FIG. 1 .
  • too thick a mat renders the board difficult to cut during installation. Such cuts are needed both for overall size and to fit the board around protrusions such as plumbing and electrical hardware.
  • the utility of the present mat is further enhanced by its relatively high air permeability.
  • air permeability During the gypsum board formation process, far more water is present in the gypsum slurry than is stochiometrically needed to drive the gypsum rehydration reaction. The excess is removed during a drying operation, and preferably escapes through the facings.
  • facers must have sufficient permeability to allow the drying to be accomplished within an acceptable time period and without bubbling, delamination, or other degradation of the facer.
  • the air permeability of a mat is conventionally measured by the air flow between reservoirs separated by the mat.
  • the Frazier test is called the Frazier test and further described by ASTM Standard Method D737, with the results ordinarily being given in units of cubic feet per minute per square foot (cfm/ft 2 ).
  • the test is usually carried out at a differential pressure of about 0.5 inches of water.
  • the permeability of the present mat is at least about 250, and more preferably, at least about 300 cfm/ft 2 .
  • any suitable method may be used to form the present mats.
  • One such method known from U.S. Pat. No. 4,129,674, employs a wet-laid, inclined wire screen mat-forming machine.
  • the method comprises forming a slurry, preferably a water slurry, containing the requisite fibers.
  • the solids content of such a slurry may be very low, such as approximately 0.2%.
  • the slurry is intensely mechanically agitated to disperse the fibers uniformly therein and then dispensed onto a moving screen.
  • a vacuum is applied to remove a substantial part of the water, which is preferably recycled, and thereby form a web of the fibers.
  • the web After application of a binder, the web is heated to evaporate any remaining water and cure the binder, thus forming the bonded mat.
  • the mat-forming process is carried out in a continuous operation.
  • the moving screen is provided as a continuous conveyor-like loop and is slightly upwardly inclined during the portion of its travel in which the fiber slurry is deposited thereon.
  • a binder is applied and the mat heated to effect final drying and curing.
  • the web is optionally transferred to one or more additional downstream conveyor systems for binder application and passage through a heated oven for the final drying and curing operation.
  • Machines suitable for carrying out such a web-forming process are available commercially and include devices manufactured under the tradenames HydroformerTM by Voith-Sulzer of Appleton, WS, and DeltaformerTM by Valmet/Sandy Hill of Glenns Falls, N.Y.
  • the aqueous binder solution is preferably applied using a curtain coater or a dip and squeeze applicator. Normally, the mat is subjected to temperatures of about 120-330° C. for periods usually not exceeding 1 or 2 minutes, and frequently less than 40 seconds, for the drying and curing operations.
  • Alternative mat forming methods useful in forming mat for the present invention include the use of well-known cylinder forming and “dry laying.”
  • the invention further provides a method for making gypsum board and other hydraulic set and cementitious board products for interior and/or exterior use, i.e. products appointed for installation on either interior or exterior surfaces of building structures.
  • exterior surface is meant any surface of a completed structure expected to be exposed to weather; by interior surface is meant a surface within the confines of an enclosed, completed structure and not intended to be exposed to weather.
  • non-woven, fibrous mat is present on at least one of the large faces of the gypsum board.
  • the present improved gypsum board production method comprises the steps of: forming an aqueous slurry comprising at least one of anhydrous calcium sulfate, calcium sulfate hemi-hydrate, and hydraulic setting cement; distributing the slurry to form a layer on a first facing; applying a second facing onto the top of the layer; separating the resultant board into individual articles; and drying the articles.
  • the process is characterized in that at least one of the facings comprises a non-woven, fibrous mat having a fibrous web comprising a blend of fibers, including a major portion of chopped continuous glass fibers and a minor amount of fine staple fibers.
  • the chopped continuous fibers have an average fiber diameter ranging from about 8 to 17 ⁇ m, and the staple fibers have an average or mean fiber diameter of less than about 5.5 ⁇ m.
  • the fibers in the web are bound together with a polymeric binder.
  • the slurry may be distributed to form a layer between two facings.
  • the slurry optionally includes reinforcing fibers or other known additives used as process control agents or to impart desired functional properties to the board, including one or more of agents such as biocides, flame retardants, and water repellants.
  • the product of the invention is ordinarily of a form known in the building trades as board, i.e. a product having a width and a length substantially greater than its thickness. Gypsum and other hydraulic set and cementitious board products are typically furnished commercially in nominal widths of at least 2 feet, and more commonly 4 feet. Lengths are generally at least 2 feet, but more commonly are 8-12 feet.
  • Gypsum and other hydraulic set boards made in accordance with the present invention exhibit a number of desirable qualities.
  • the fibrous mat used results in a surface that is smoother and more amenable to painting or other surface finishing processes than prior art boards,
  • the mat is also more flexible, facilitating the bending operations needed to fold the facer around the core during production, as illustrated for mat 14 in FIG. 1 .
  • board incorporating the fibrous mat of the invention has a reduced tendency to generate irritating dust during cutting and handling than prior art boards faced with other facing materials.
  • any known process for making mat faced gypsum board can be used along with the mats described for facing at least one major face of the gypsum boards of the present invention.
  • those processes described in U.S. Pat. Nos. 4,647,496, 5,220,762, 6,524,679, all herein incorporated by reference, are typical, but the method of the present invention is not limited to only these known processes of making fibrous mat faced gypsum board.
  • a non-woven glass fiber mat of a type typically used as a facer for conventional gypsum board is prepared using a wet laid mat machine in the manner disclosed in U.S. Pat. No. 4,129,674, which is hereby incorporated in the entirety by reference thereto.
  • the mat designated as comparative example 1, contains chopped glass fibers and is bonded together with a polymer binder containing a small amount of water repellant.
  • the specific materials used are set forth in Table I.
  • the M137 and K137 glass fibers are commercially available from the Johns Manville Corporation of Denver, Colo.
  • a conventional modified urea formaldehyde binder is applied with a curtain coating/saturation technique.
  • Standard tests for characterizing the physical and mechanical properties are carried out on the comparative example mat, including basis weight per unit area, loss of weight on ignition, and thickness. Strengths are measured both along the web direction and across the web, using a conventional mechanical testing machine to determine the peak tensile strength of a sample about 7.5 cm wide. The stiffness is determined using the standard Taber stiffness test, wherein a 38 mm wide strip is deflected by applying force at a point 50 mm from a clamping point. The torque (in g-cm) required to achieve a 15 deflection is conventionally termed the Taber stiffness. Air permeability is measured using the Frazier test at a differential pressure of 0.5 inches of water in accordance with ASTM Method D737.
  • Examples 2-5 Four non-woven fiberglass mats designated as Examples 2-5 are formed using a wet laid mat machine in the manner disclosed in U.S. Pat. No. 4,129,674. Each mat contains a blend of glass fibers of various average fiber diameters as set forth in Table III.
  • Examples 2-3 contain a blend of about 75 weight percent of fiber content H 137 chopped glass fibers about 12 mm long and having an average fiber diameter of about 11 ⁇ m, and about 25 wt. percent fiber content of CX 253 glass staple fiber having an average fiber diameter of about 5 ⁇ m. Both fibers are available from Johns Manville Corporation of Denver, Colo. The fibers make up about 73 ⁇ 1.5 wt. percent of the mat, based on the weight of the dry mat. The mat is made on a wet-laid, inclined wire screen mat forming machine. The fibers are bonded together with about 26 ⁇ 1.5 wt.
  • a cured modified acrylic binder composed of HycarTM 26138, an acrylic resin latex having a glass transition temperature of about 25° C., and about 2.5 wt. % melamine formaldehyde.
  • the HycarTM 26138 resin latex is available from Noveon, Inc. of Cleveland, Ohio. A curtain coating/saturation technique is used to apply the binder.
  • Examples 4-5 contain a blend of about 75 weight percent H 137 chopped glass fibers about 12 mm long and having an average fiber diameter of about 11 ⁇ m, and about 25 wt. percent of 210X glass staple fiber having an average fiber diameter of about 3 ⁇ m. Both fibers are available from Johns Manville Corporation of Denver, Colo. The fibers make up about 71 ⁇ 1.5 wt. percent of the mat, based on the weight of the dry mat. They are bonded together with about 29 ⁇ 1.5 wt. percent of the same HycarTM 26138 used in preparing the mats of Examples 3-4. The mat formation and binder application techniques are the same as for preparing the mats of Examples 2-3.
  • the mats of the above Comparative Example 1 and Examples 3 and 5 of the invention are used as facers for the manufacture of gypsum board in a manner as disclosed in U.S. Pat. No. 4,647,496. Smoothness is determined by relative ranking of samples observed for shadows cast by surface irregularities when viewed under low incident light angle. Samples with deeper surface or non-uniform irregularities are ranked lower than shallow or uniform irregularity. Samples are ranked on a scale of 1-10 with 10 being completely smooth.
  • the mats of Examples 3 and 5 produce gypsum board having smoothnesses rated at 7 and 5, respectively, and are therefore smoother than board made with the mat of Comparative Example 1, which has a smoothness rating of 4. It is unexpected and surprising that the smoothness of the dry cured mat is not indicative of the smoothness of that same surface after the mat passes through the gypsum board manufacturing process.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Civil Engineering (AREA)
  • Laminated Bodies (AREA)
  • Paper (AREA)
  • Finishing Walls (AREA)
  • Nonwoven Fabrics (AREA)
US10/608,790 2003-06-27 2003-06-27 Non-woven glass fiber mat faced gypsum board and process of manufacture Expired - Lifetime US7842629B2 (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US10/608,790 US7842629B2 (en) 2003-06-27 2003-06-27 Non-woven glass fiber mat faced gypsum board and process of manufacture
PL04754709T PL1644167T3 (pl) 2003-06-27 2004-06-07 Płyta gipsowa obłożona matą z włókniny z włókna szklanego i sposób wytwarzania
EP04754709.6A EP1644167B1 (fr) 2003-06-27 2004-06-07 Plaque de platre revetue d'un mat de fibres de verre non tisse, et son procede de fabrication
CA 2529627 CA2529627C (fr) 2003-06-27 2004-06-07 Plaque de platre revetue d'un mat de fibres de verre non tisse, et son procede de fabrication
TR2018/19200T TR201819200T4 (tr) 2003-06-27 2004-06-07 Dokunmamış Cam Elyaf Keçe Kaplamalı Alçı Levha Ve Üretim İşlemi
RU2006102359A RU2348532C2 (ru) 2003-06-27 2004-06-07 Гипсовая панель, облицованная матом нетканого стекловолокнистого материала, и способ изготовления
PCT/US2004/018178 WO2005005117A2 (fr) 2003-06-27 2004-06-07 Plaque de platre revetue d'un mat de fibres de verre non tisse, et son procede de fabrication
ES04754709T ES2711228T3 (es) 2003-06-27 2004-06-07 Placa de yeso revestida de esterilla de fibra de vidrio no tejido y procedimiento de fabricación

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/608,790 US7842629B2 (en) 2003-06-27 2003-06-27 Non-woven glass fiber mat faced gypsum board and process of manufacture

Publications (2)

Publication Number Publication Date
US20040266304A1 US20040266304A1 (en) 2004-12-30
US7842629B2 true US7842629B2 (en) 2010-11-30

Family

ID=33540680

Family Applications (1)

Application Number Title Priority Date Filing Date
US10/608,790 Expired - Lifetime US7842629B2 (en) 2003-06-27 2003-06-27 Non-woven glass fiber mat faced gypsum board and process of manufacture

Country Status (8)

Country Link
US (1) US7842629B2 (fr)
EP (1) EP1644167B1 (fr)
CA (1) CA2529627C (fr)
ES (1) ES2711228T3 (fr)
PL (1) PL1644167T3 (fr)
RU (1) RU2348532C2 (fr)
TR (1) TR201819200T4 (fr)
WO (1) WO2005005117A2 (fr)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2612969A3 (fr) * 2012-01-09 2013-11-06 Johns Manville Parements renforcés de fibres contenant des microfibres et leur procédé de fabrication
EP2690217A1 (fr) * 2012-07-25 2014-01-29 Johns Manville Tapis de parement en fibres de verre
US8734613B1 (en) 2013-07-05 2014-05-27 Usg Interiors, Llc Glass fiber enhanced mineral wool based acoustical tile
CN103979904A (zh) * 2013-08-02 2014-08-13 上海纯翠装饰材料有限公司 增强玻璃纤维高强石膏板
US20170260748A1 (en) * 2016-03-10 2017-09-14 Carlisle Intangible Company Heating compensating roofing boards
US10272399B2 (en) 2016-08-05 2019-04-30 United States Gypsum Company Method for producing fiber reinforced cementitious slurry using a multi-stage continuous mixer
US10336036B2 (en) 2013-03-15 2019-07-02 United States Gypsum Company Cementitious article comprising hydrophobic finish
US10981294B2 (en) 2016-08-05 2021-04-20 United States Gypsum Company Headbox and forming station for fiber-reinforced cementitious panel production
US11173629B2 (en) 2016-08-05 2021-11-16 United States Gypsum Company Continuous mixer and method of mixing reinforcing fibers with cementitious materials
US11224990B2 (en) 2016-08-05 2022-01-18 United States Gypsum Company Continuous methods of making fiber reinforced concrete panels
US11225793B2 (en) 2018-04-27 2022-01-18 United States Gypsum Company Fly ash-free coating formulation for fibrous mat tile backerboard

Families Citing this family (44)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7208225B2 (en) * 1995-06-30 2007-04-24 Lafarge Platres Prefabricated plaster board
US6723670B2 (en) * 2001-08-07 2004-04-20 Johns Manville International, Inc. Coated nonwoven fiber mat
US20040161993A1 (en) * 2001-09-06 2004-08-19 Gary Tripp Inorganic fiber insulation made from glass fibers and polymer bonding fibers
US20040192141A1 (en) * 2001-09-06 2004-09-30 Alain Yang Sub-layer material for laminate flooring
US20030041626A1 (en) * 2001-09-06 2003-03-06 Certainteed Corporation Insulation containing a mixed layer of textile fibers and of rotary and/or flame attenuated fibers, and process for producing the same
US20040163724A1 (en) * 2001-09-06 2004-08-26 Mark Trabbold Formaldehyde-free duct liner
US20040209074A1 (en) * 2003-04-17 2004-10-21 Georgia-Pacific Gypsum Corporation Mat faced gypsum board
US7989370B2 (en) * 2003-10-17 2011-08-02 Georgia-Pacific Gypsum Llc Interior wallboard and method of making same
US20050202227A1 (en) * 2004-03-10 2005-09-15 Kajander Richard E. Silane based coatings on glass fiber reinforcements in gypsum board
US7745357B2 (en) 2004-03-12 2010-06-29 Georgia-Pacific Gypsum Llc Use of pre-coated mat for preparing gypsum board
WO2005094161A2 (fr) 2004-03-30 2005-10-13 Coveright Surfaces Holding Gmbh Composition de revetement, article revetu et procede d'obtention de ceux-ci
US7846536B2 (en) * 2004-12-16 2010-12-07 United States Gypsum Company Building panels with aesthetic edges
US7635657B2 (en) * 2005-04-25 2009-12-22 Georgia-Pacific Gypsum Llc Interior wallboard and method of making same
CA2629708C (fr) * 2005-11-09 2015-09-22 Yoshino Gypsum Co., Ltd. Composition pour materiau de construction et plaque de platre et procede de construction les utilisant et mur et element similaire
US20080003903A1 (en) * 2005-12-21 2008-01-03 Malay Nandi Coated nonwoven mat
US20070141931A1 (en) * 2005-12-21 2007-06-21 Malay Nandi Faced board material having a smooth aesthetically pleasing outer surface and good adhesion of facer to core
US20070141304A1 (en) * 2005-12-21 2007-06-21 Gaurav Agrawal Perforated board formed from cementitious material and process and system for producing same
US20070149083A1 (en) * 2005-12-22 2007-06-28 Gaurav Agrawal Board formed from a cementitious material and a facer containing a laminate
US20070148430A1 (en) * 2005-12-22 2007-06-28 Gaurav Agrawal Perforated, coated nonwoven mat
US20070175173A1 (en) * 2005-12-30 2007-08-02 Babineau Francis J Jr Board construction assembly for reducing sound transmission and method
US20070197114A1 (en) * 2006-02-23 2007-08-23 Grove Dale A Wear resistant coating composition for a veil product
US20080152945A1 (en) * 2006-12-20 2008-06-26 David Paul Miller Fiber reinforced gypsum panel
US8070895B2 (en) 2007-02-12 2011-12-06 United States Gypsum Company Water resistant cementitious article and method for preparing same
WO2008101679A2 (fr) * 2007-02-21 2008-08-28 Johns Manville Europe Gmbh Matériaux composites décorables directement, procédé pour leur fabrication et leur utilisation
US7829488B2 (en) * 2008-01-22 2010-11-09 Johns Manville Non-woven glass fiber mat faced gypsum board and process of manufacture
WO2010051364A1 (fr) * 2008-10-30 2010-05-06 United States Gypsum Company Article cimentaire revêtu de mat et son procédé de fabrication
US8590268B2 (en) * 2008-11-21 2013-11-26 Maxxon Corporation Installing underlayment systems
US8329308B2 (en) 2009-03-31 2012-12-11 United States Gypsum Company Cementitious article and method for preparing the same
WO2011019598A1 (fr) 2009-08-11 2011-02-17 Johns Manville Liant durcissable pour fibre de verre
DE102011011056A1 (de) * 2011-02-11 2012-08-16 Johns Manville Europe Gmbh Glasfaservlies sowie Glasfaservliese enthaltende Erzeugnisse
RU2529687C2 (ru) * 2012-04-24 2014-09-27 Александр Витольдович Малицкий Композитный слоистый материал (варианты)
GB201309058D0 (en) * 2013-05-20 2013-07-03 Bpb United Kingdom Ltd Composite construction panel having improved substrate board and method for the manufacture thereof
US10378135B2 (en) * 2013-08-06 2019-08-13 Johns Manville Glass fibre mat and products containing glass fibre mats
DE102013013321A1 (de) * 2013-08-09 2015-02-12 Johns Manville Europe Gmbh Faservlies sowie Faservliese enthaltende Erzeugnisse
KR102233322B1 (ko) 2013-10-16 2021-03-26 오씨브이 인텔렉츄얼 캐피탈 엘엘씨 가요성의 부직포 매트
WO2015167362A1 (fr) * 2014-04-30 2015-11-05 Александр Витольдович МАЛИЦКИЙ Panneau de construction en bois à claire-voie (et variantes)
JP6453703B2 (ja) * 2015-04-28 2019-01-16 帝人株式会社 Ｆｒｐパネル及びその製造方法
WO2017139270A1 (fr) * 2016-02-08 2017-08-17 Certainteed Gypsum, Inc. Système, procédé et appareil pour plaque de plâtre avec structure intégrée ayant des cellules ouvertes sensiblement remplies
CN105904795B (zh) * 2016-05-18 2018-08-14 盐城市悦诚新材料股份有限公司 无纺布覆膜防护板
CN106739210A (zh) * 2016-12-12 2017-05-31 王成英 一种防渗透的防火板及其生产方法
US10562206B2 (en) 2017-06-05 2020-02-18 National Gypsum Properties, Llc Cementitious panels, and systems and methods for manufacturing cementitious panels
CN108166695A (zh) * 2017-12-21 2018-06-15 泰山石膏有限公司 一种表面具有复合玻璃纤维贴面毡的石膏板材
CN108775124A (zh) * 2018-08-08 2018-11-09 郑州三迪建筑科技有限公司 一种网面石膏板用网格布
CA3156002A1 (fr) * 2019-09-27 2021-04-01 Owens Corning Intellectual Capital, Llc Natte de fibres non tisse non revetu

Citations (39)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4195110A (en) 1973-11-12 1980-03-25 United States Gypsum Company Glass-reinforced composite gypsum board
US4637951A (en) * 1984-12-24 1987-01-20 Manville Sales Corporation Fibrous mat facer with improved strike-through resistance
US4647496A (en) * 1984-02-27 1987-03-03 Georgia-Pacific Corporation Use of fibrous mat-faced gypsum board in exterior finishing systems for buildings
US4722866A (en) 1985-04-09 1988-02-02 Georgia-Pacific Corporation Fire resistant gypsum board
US4784897A (en) 1984-03-12 1988-11-15 Fiebig & Schillings Gmbh Cover layer material on a basis of matting or fabric
US4879173A (en) 1988-01-06 1989-11-07 Georgia-Pacific Corporation Glass mat with reinforcing binder
US5079078A (en) 1990-01-29 1992-01-07 Owens-Corning Fiberglas Corp. Fire-resistant panel system
US5148645A (en) 1984-02-27 1992-09-22 Georgia-Pacific Corporation Use of fibrous mat-faced gypsum board in shaft wall assemblies and improved fire resistant board
US5173364A (en) 1990-04-12 1992-12-22 Redco, N.V. Glass fibre reinforced plasterboard and a method for producing same
US5220762A (en) 1984-02-27 1993-06-22 Georgia-Pacific Corporation Fibrous mat-faced gypsum board in exterior and interior finishing systems for buildings
US5371989A (en) 1984-02-27 1994-12-13 Georgia-Pacific Corporation Use of fibrous mat-faced gypsum board in exterior finishing systems for buildings and shaft wall assemblies
US5389716A (en) * 1992-06-26 1995-02-14 Georgia-Pacific Resins, Inc. Fire resistant cured binder for fibrous mats
US5395685A (en) 1989-11-10 1995-03-07 Gebruder Knauf Westdeutsche Gipswerke Kg Gypsum board comprisiing linings made of glass fiber non-wovens coated with an inorganic cement binder
US5397631A (en) 1987-11-16 1995-03-14 Georgia-Pacific Corporation Coated fibrous mat faced gypsum board resistant to water and humidity
US5735092A (en) 1996-09-23 1998-04-07 Bridgestone/Firestone, Inc. Composite roofing members having improved dimensional stability and related methods
US5772846A (en) 1997-01-09 1998-06-30 Johns Manville International, Inc. Nonwoven glass fiber mat for facing gypsum board and method of making
US5791109A (en) 1984-02-27 1998-08-11 Georgia-Pacific Corporation Gypsum board and finishing system containing same
US5883024A (en) 1995-06-07 1999-03-16 G-P Gypsum Corporation Fibrous mat and mat-faced gypsum board
US5891563A (en) 1996-10-08 1999-04-06 Bridgestone/Firestone, Inc. Polyisocyanurate boards with reduced moisture absorbency and lower air permeability and related methods
US6001496A (en) 1995-08-18 1999-12-14 G-P Gypsum Corporation Mat-faced gypsum board and method of manufacturing same
US6044604A (en) 1996-09-23 2000-04-04 Bridgestone/Firestone, Inc. Composite roofing members having improved dimensional stability and related methods
US6110575A (en) 1996-11-12 2000-08-29 Yoshino Sangyo Co., Ltd. Gypsum-based composite article and method for producing same
US6187697B1 (en) 1998-12-31 2001-02-13 Alan Michael Jaffee Multiple layer nonwoven mat and laminate
US6294253B1 (en) 1999-08-11 2001-09-25 Johns Manville International, Inc. Uniformly dispersing fibers
US6365533B1 (en) * 1998-09-08 2002-04-02 Building Materials Investment Corportion Foamed facer and insulation boards made therefrom cross-reference to related patent application
US6368991B1 (en) 1998-09-08 2002-04-09 Building Materials Investment Corporation Foamed facer and insulation boards made therefrom
US20030032351A1 (en) 1998-09-08 2003-02-13 Horner Charles J. Foamed facer and insulation boards made therefrom
US20030032350A1 (en) * 2001-08-07 2003-02-13 Kajander Richard Emil Method of making foam coated mat online and coated mat product
US6524679B2 (en) 2001-06-06 2003-02-25 Bpb, Plc Glass reinforced gypsum board
US6579413B1 (en) 2002-03-21 2003-06-17 Owens Corning Fiberglas Technology, Inc. Wet-formed mat applications for cement backerboards
US6770354B2 (en) 2001-04-19 2004-08-03 G-P Gypsum Corporation Mat-faced gypsum board
US6800361B2 (en) 2002-06-14 2004-10-05 E. I. Du Pont De Nemours And Company Gypsum board having improved flexibility, toughness, abuse resistance, water resistance and fire resistance
US20040209071A1 (en) * 2003-04-17 2004-10-21 Usg Interiors, Inc. Mold resistant acoustical panel
US6841230B2 (en) 2001-11-29 2005-01-11 Ts Tech Co., Ltd. Long-fiber-reinforced thermoplastice resin sheets, production process thereof, and composite structures reinforced by the sheets
US20050079335A1 (en) 2003-10-10 2005-04-14 Wilkins Rodney R. Reinforcing-thermoplastic mat and method of forming such a mat
US20050155198A1 (en) 1997-01-24 2005-07-21 Bpb Plc And Moy Isover Limited Non-woven inorganic fiber mat
US20050202258A1 (en) 2004-03-10 2005-09-15 Swales Timothy G. Glass fibers and mats having improved surface structures in gypsum boards
US20050221705A1 (en) 2004-03-30 2005-10-06 Hitch James M Nonwoven fiber mats with smooth surfaces and method
US20050238863A1 (en) 2004-04-27 2005-10-27 Swales Timothy G Non-woven glass mat with dissolvable binder system for fiber-reinforced gypsum board

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4129674A (en) 1972-10-27 1978-12-12 Johns-Manville Corporation Fibrous mat especially suitable for roofing products and a method of making the mat
US4167404A (en) 1977-03-24 1979-09-11 Johns-Manville Corporation Method and apparatus for collecting fibrous material
US4772846A (en) * 1986-12-29 1988-09-20 Hughes Aircraft Company Wafer alignment and positioning apparatus for chip testing by voltage contrast electron microscopy
DE4110622C2 (de) * 1991-04-02 1995-12-21 Schoeller Felix Jun Papier Polyolefin-beschichteter Schichtträger für fotografische Aufzeichnungsmaterialien
US5308692A (en) * 1992-06-26 1994-05-03 Herbert Malarkey Roofing Company Fire resistant mat
US5840413A (en) 1993-07-13 1998-11-24 Johns Manville International, Inc. Fire retardant nonwoven mat and method of making
GB9319205D0 (en) * 1993-09-16 1993-11-03 Brown Jonathon L Cement products and a method of manufacture thereof
WO1999016984A1 (fr) * 1997-09-26 1999-04-08 Ibiden Co., Ltd. Materiau de construction refractaire composite, son procede fabrication, plaque de platre et composition resineuse

Patent Citations (45)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4195110A (en) 1973-11-12 1980-03-25 United States Gypsum Company Glass-reinforced composite gypsum board
US5220762A (en) 1984-02-27 1993-06-22 Georgia-Pacific Corporation Fibrous mat-faced gypsum board in exterior and interior finishing systems for buildings
US4647496A (en) * 1984-02-27 1987-03-03 Georgia-Pacific Corporation Use of fibrous mat-faced gypsum board in exterior finishing systems for buildings
US5791109A (en) 1984-02-27 1998-08-11 Georgia-Pacific Corporation Gypsum board and finishing system containing same
US5371989A (en) 1984-02-27 1994-12-13 Georgia-Pacific Corporation Use of fibrous mat-faced gypsum board in exterior finishing systems for buildings and shaft wall assemblies
US5148645A (en) 1984-02-27 1992-09-22 Georgia-Pacific Corporation Use of fibrous mat-faced gypsum board in shaft wall assemblies and improved fire resistant board
US4784897A (en) 1984-03-12 1988-11-15 Fiebig & Schillings Gmbh Cover layer material on a basis of matting or fabric
US4637951A (en) * 1984-12-24 1987-01-20 Manville Sales Corporation Fibrous mat facer with improved strike-through resistance
US4722866A (en) 1985-04-09 1988-02-02 Georgia-Pacific Corporation Fire resistant gypsum board
US5397631A (en) 1987-11-16 1995-03-14 Georgia-Pacific Corporation Coated fibrous mat faced gypsum board resistant to water and humidity
US5981406A (en) 1988-01-06 1999-11-09 G-P Gypsum Corporation Glass mat with reinforcing binder
US5342680A (en) 1988-01-06 1994-08-30 Georgia-Pacific Corporation Glass mat with reinforcing binder
US4879173A (en) 1988-01-06 1989-11-07 Georgia-Pacific Corporation Glass mat with reinforcing binder
US5395685A (en) 1989-11-10 1995-03-07 Gebruder Knauf Westdeutsche Gipswerke Kg Gypsum board comprisiing linings made of glass fiber non-wovens coated with an inorganic cement binder
US5079078A (en) 1990-01-29 1992-01-07 Owens-Corning Fiberglas Corp. Fire-resistant panel system
US5173364A (en) 1990-04-12 1992-12-22 Redco, N.V. Glass fibre reinforced plasterboard and a method for producing same
US5389716A (en) * 1992-06-26 1995-02-14 Georgia-Pacific Resins, Inc. Fire resistant cured binder for fibrous mats
US5883024A (en) 1995-06-07 1999-03-16 G-P Gypsum Corporation Fibrous mat and mat-faced gypsum board
US6001496A (en) 1995-08-18 1999-12-14 G-P Gypsum Corporation Mat-faced gypsum board and method of manufacturing same
US6044604A (en) 1996-09-23 2000-04-04 Bridgestone/Firestone, Inc. Composite roofing members having improved dimensional stability and related methods
US5735092A (en) 1996-09-23 1998-04-07 Bridgestone/Firestone, Inc. Composite roofing members having improved dimensional stability and related methods
US5891563A (en) 1996-10-08 1999-04-06 Bridgestone/Firestone, Inc. Polyisocyanurate boards with reduced moisture absorbency and lower air permeability and related methods
US6110575A (en) 1996-11-12 2000-08-29 Yoshino Sangyo Co., Ltd. Gypsum-based composite article and method for producing same
US5772846A (en) 1997-01-09 1998-06-30 Johns Manville International, Inc. Nonwoven glass fiber mat for facing gypsum board and method of making
US20050155198A1 (en) 1997-01-24 2005-07-21 Bpb Plc And Moy Isover Limited Non-woven inorganic fiber mat
US6365533B1 (en) * 1998-09-08 2002-04-02 Building Materials Investment Corportion Foamed facer and insulation boards made therefrom cross-reference to related patent application
US6368991B1 (en) 1998-09-08 2002-04-09 Building Materials Investment Corporation Foamed facer and insulation boards made therefrom
US20030032351A1 (en) 1998-09-08 2003-02-13 Horner Charles J. Foamed facer and insulation boards made therefrom
US6187697B1 (en) 1998-12-31 2001-02-13 Alan Michael Jaffee Multiple layer nonwoven mat and laminate
US6294253B1 (en) 1999-08-11 2001-09-25 Johns Manville International, Inc. Uniformly dispersing fibers
US6521086B2 (en) 1999-08-11 2003-02-18 Johns Manville International, Inc. Method of dispersing fibers
US6770354B2 (en) 2001-04-19 2004-08-03 G-P Gypsum Corporation Mat-faced gypsum board
US6878321B2 (en) 2001-06-06 2005-04-12 Bpb Plc Method of manufacture of glass reinforced gypsum board and apparatus therefor
US6524679B2 (en) 2001-06-06 2003-02-25 Bpb, Plc Glass reinforced gypsum board
US6723670B2 (en) * 2001-08-07 2004-04-20 Johns Manville International, Inc. Coated nonwoven fiber mat
US20030032350A1 (en) * 2001-08-07 2003-02-13 Kajander Richard Emil Method of making foam coated mat online and coated mat product
US6841230B2 (en) 2001-11-29 2005-01-11 Ts Tech Co., Ltd. Long-fiber-reinforced thermoplastice resin sheets, production process thereof, and composite structures reinforced by the sheets
US6579413B1 (en) 2002-03-21 2003-06-17 Owens Corning Fiberglas Technology, Inc. Wet-formed mat applications for cement backerboards
US6800361B2 (en) 2002-06-14 2004-10-05 E. I. Du Pont De Nemours And Company Gypsum board having improved flexibility, toughness, abuse resistance, water resistance and fire resistance
US20040209071A1 (en) * 2003-04-17 2004-10-21 Usg Interiors, Inc. Mold resistant acoustical panel
US20050079335A1 (en) 2003-10-10 2005-04-14 Wilkins Rodney R. Reinforcing-thermoplastic mat and method of forming such a mat
US20050079786A1 (en) 2003-10-10 2005-04-14 Wilkins Rodney R. Fiberglass-polypropylene mat and method of forming a fiberglass-polypropylene mat
US20050202258A1 (en) 2004-03-10 2005-09-15 Swales Timothy G. Glass fibers and mats having improved surface structures in gypsum boards
US20050221705A1 (en) 2004-03-30 2005-10-06 Hitch James M Nonwoven fiber mats with smooth surfaces and method
US20050238863A1 (en) 2004-04-27 2005-10-27 Swales Timothy G Non-woven glass mat with dissolvable binder system for fiber-reinforced gypsum board

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
"Microdenier", Complete Textile Glossary, Celanese Acetate, 2001. *
Johns Manville Product Information: Glass Fiber Mats, Dura Glass® 7529.

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2612969A3 (fr) * 2012-01-09 2013-11-06 Johns Manville Parements renforcés de fibres contenant des microfibres et leur procédé de fabrication
US9267238B2 (en) 2012-07-25 2016-02-23 Johns Manville Glass fiber reinforced facer mat
EP2690217A1 (fr) * 2012-07-25 2014-01-29 Johns Manville Tapis de parement en fibres de verre
US10428450B2 (en) 2012-07-25 2019-10-01 Johns Manville Glass fiber reinforced facer mat
US10336036B2 (en) 2013-03-15 2019-07-02 United States Gypsum Company Cementitious article comprising hydrophobic finish
US8734613B1 (en) 2013-07-05 2014-05-27 Usg Interiors, Llc Glass fiber enhanced mineral wool based acoustical tile
CN103979904B (zh) * 2013-08-02 2016-04-13 上海纯翠装饰材料有限公司 增强玻璃纤维高强石膏板
CN103979904A (zh) * 2013-08-02 2014-08-13 上海纯翠装饰材料有限公司 增强玻璃纤维高强石膏板
US20170260748A1 (en) * 2016-03-10 2017-09-14 Carlisle Intangible Company Heating compensating roofing boards
US10662652B2 (en) * 2016-03-10 2020-05-26 Carlisle Intangible Company Heating compensating roofing boards
US10272399B2 (en) 2016-08-05 2019-04-30 United States Gypsum Company Method for producing fiber reinforced cementitious slurry using a multi-stage continuous mixer
US10646837B2 (en) 2016-08-05 2020-05-12 United States Gypsum Company Method for producing fiber reinforced cementitious slurry using a multi-state continuous mixer
US10981294B2 (en) 2016-08-05 2021-04-20 United States Gypsum Company Headbox and forming station for fiber-reinforced cementitious panel production
US11173629B2 (en) 2016-08-05 2021-11-16 United States Gypsum Company Continuous mixer and method of mixing reinforcing fibers with cementitious materials
US11224990B2 (en) 2016-08-05 2022-01-18 United States Gypsum Company Continuous methods of making fiber reinforced concrete panels
US11225793B2 (en) 2018-04-27 2022-01-18 United States Gypsum Company Fly ash-free coating formulation for fibrous mat tile backerboard

Also Published As

Publication number Publication date
EP1644167A2 (fr) 2006-04-12
WO2005005117A2 (fr) 2005-01-20
WO2005005117A3 (fr) 2005-06-16
CA2529627A1 (fr) 2005-01-20
TR201819200T4 (tr) 2019-01-21
CA2529627C (fr) 2011-05-03
RU2348532C2 (ru) 2009-03-10
ES2711228T3 (es) 2019-04-30
EP1644167A4 (fr) 2008-05-21
EP1644167B1 (fr) 2018-11-14
PL1644167T3 (pl) 2019-05-31
RU2006102359A (ru) 2006-06-27
US20040266304A1 (en) 2004-12-30

Similar Documents

Publication Publication Date Title
US7842629B2 (en) Non-woven glass fiber mat faced gypsum board and process of manufacture
US8128767B2 (en) Process for manufacturing gypsum board faced with non-woven glass fiber mat
US7829488B2 (en) Non-woven glass fiber mat faced gypsum board and process of manufacture
EP1800853B1 (fr) Matériau pour plaque
US20080003903A1 (en) Coated nonwoven mat
US6737156B2 (en) Interior wallboard and method of making same
US7338702B2 (en) Non-woven glass mat with dissolvable binder system for fiber-reinforced gypsum board
US7700505B2 (en) Gypsum board and systems comprising it
US20070149078A1 (en) Perforated non-woven fiberglass mat
US5883024A (en) Fibrous mat and mat-faced gypsum board
US20070148430A1 (en) Perforated, coated nonwoven mat
CA1308344C (fr) Produit stratifie en platre
EP2612969B1 (fr) Parements renforcés de fibres contenant des microfibres et leur procédé de fabrication
CN111439013A (zh) 适用于湿润或潮湿区域的石膏板
JP2012507421A (ja) マット張り表面を有するセメント質物品およびその製造方法
MXPA97009639A (en) Improved fibrous mat and plaster tablet covered with est

Legal Events

Date Code Title Description
AS Assignment

Owner name: JOHNS MANVILLE INTERNATIONAL, INC., COLORADO

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:JAFFEE, ALAN MICHAEL;REEL/FRAME:014676/0541

Effective date: 20030820

STCF Information on status: patent grant

Free format text: PATENTED CASE

FPAY Fee payment

Year of fee payment: 4

MAFP Maintenance fee payment

Free format text: PAYMENT OF MAINTENANCE FEE, 8TH YEAR, LARGE ENTITY (ORIGINAL EVENT CODE: M1552)

Year of fee payment: 8

MAFP Maintenance fee payment

Free format text: PAYMENT OF MAINTENANCE FEE, 12TH YEAR, LARGE ENTITY (ORIGINAL EVENT CODE: M1553); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

Year of fee payment: 12